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Service Manual
OT III
Transfer Switch
40 to 1000 Amperes
962-0512 6-2001
Printed in U.S.A. Begin Spec G
PURPOSE
This supplement covers OT III transfer switches that are intended for use
in fire pump controller applications — in accordance with NFPA 20. This
supplement also covers the required phase sequence monitor.
OT III Transfer Switches TABLE 1. ATS SIZING FOR FIRE PUMP MOTORS
In Fire Pump Circuit Applications
Fire Pump 208 V ATS: 480 V ATS:
Figure 1 illustrates the typical fire pump controller / Motor HP Rated Amps Rated Amps
transfer switch arrangement. 15 70 40
Required Transfer Switch Features 20 70 40
1. An OT III with a standard Power Sentry control 25 125 40
(one ATS per fire pump).
30 125 70
2. Programmed Transition module.
40 150 70
3. Phase Sequence monitor (see page 3).
50 225 125
4. Momentary Test switch (on cabinet door).
5. UL Type 3R, 4, or 12 cabinet. 60 225 125
In accordance with NFPA 20, the transfer switch 100 400 150
must be rated for at least 115% of the pump motor 125 400 225
full load amperes (FLA). Use the motor nameplate 150 600 225
FLA, if available. As an alternative, use Table 1.
200 800 300
NFPA 20 requires any upstream overcurrent pro-
Based on NEC Table 430-150 Full Load
tective device (fuse or circuit breaker) on the utility
Current Three-Phase AC Motors
source side to be sized to carry fire pump locked ro-
tor current continuously. As a result, this upstream Supervision
overcurrent protective device (OCD) may be signifi-
The isolating switch auxiliary contacts must be con-
cantly oversized.
nected to the ATS controls to prevent generator set
Verify that the upstream OCD on the utility source starting when the isolating switch is open. Refer to
side is within the the maximum ampere rating al- the site interconnection drawing.
lowed for withstand and closing rating (WCR) of the
Marking
ATS. If it is not, oversize the ATS as necessary.
The generator side isolating switch must be marked
Location with a caution that, prior to servicing, both the gen-
The ATS and emergency side isolating switch must erator side isolating switch and the fire pump con-
be located in the fire pump room. troller isolating switch must be opened.
Isolating Switch Separate ATS for Auxiliaries
The contractor must furnish and install a lockable A separate ATS must supply all pump room auxilia-
isolating switch, with auxiliary contacts, on the gen- ries.
erator side of the ATS. See Figure 1.
Page 2ofof
Redistribution or publication 3 document
this
by any means, is strictly prohibited.
NORMAL FIRE PUMP ALTERNATE
SOURCE FEEDER SOURCE
BREAKER(B,C)
NOTE (A)
GENERATOR
ISOLATING
FIRE PUMP SWITCH
SERVICE DISCONNECT NORMAL GENERATOR
UPSTREAM SOURCE FEEDER
OVERCURRENT DEVICE BREAKER(C)
(fuse or circuit breaker)
NOTE (A) N E
PUMP ROOM
N E
TRANSFER TO OTHER
SWITCH LOADS
PUMP ROOM
FIRE PUMP
CONTROLLER
(A) “Outside building or fire rated runs”
Ref: NFPA 20 - 1993 6_3.1.1.
Page of
Redistribution or publication 3 of
this3document
by any means, is strictly prohibited.
Phase Sequence Monitor
The phase sequence monitor (Figure 2) is con- A Phase B Phase C Phase
nected to—and senses—A, B, and C phases of util-
ity power. If there is a phase reversal or a loss of one
phase, a normally energized relay drops out, clos-
ing a set of contacts. These relay contacts are wired
to the remote test input terminals (7 and 8) of TB2.
When the contacts across terminals 7 and 8 of TB2
close, the generator set start/transfer of load se-
quence is initiated.
The Relay Energized LED is lit during normal op-
eration.
In the event that an under voltage, phase reversal, or TURN FULL
loss of one phase is sensed, relay dropout occurs COUNTER-CLOCK-
within 500 milliseconds on models up to 300 VAC — WISE
and within 2.0 seconds on models over 300 VAC.
The phase sequence monitor relay has an under-
voltage sensing circuit that causes the relay to drop
out when 3-phase voltage falls below 90% of nomi-
nal. If improperly set, this could over-ride the Power
Sentry voltage sensor. TO TB2, 7 & 8 307-2840 - 02
To prevent this occurrence, turn the nominal voltage FIGURE 2. PHASE SEQUENCE MONITOR
adjust potentiometer on the phase sequence moni-
tor relay fully counter-clockwise, and adjust the
Power Sentry undervoltage dropout setting to a
higher voltage.
If improperly adjusted, the phase
sequence monitor could over-ride the Power
Sentry undervoltage setting—possibly result-
ing in the generator set being started in unin-
tended situations. To prevent this occurrence,
adjust the relay to a voltage lower than the Pow-
er Sentry setting.
PURPOSE
A new exerciser/change-over clock is available that requires new programming instructions.
If the exerciser/change-over clock in the transfer switch matches the one shown in Figure 1 of
this supplement, follow the programming instructions provided in this supplement.
Keep this copy with the transfer switch manuals for future reference.
iii OT3-UG-3
Redistribution or publication of this document
by any means, is strictly prohibited.
iv Redistribution or publication of this document
by any means, is strictly prohibited.
1. Introduction
ABOUT THIS MANUAL
NORMAL
This manual contains service procedures for an OT
transfer switch. Sections 1, 2, 3, and 4 cover the
utility-to-generator set automatic transfer switch.
Although much of the information on theory of op-
eration, Power Sentry calibration, and trouble-
shooting in sections 1, 2, and 3 is applicable to gen-
erator set-to-generator set, utility-to-utility, and non-
automatic/remote configurations; there are several
significant differences. LOAD
There are four indicator lamps on the cabinet door. Optional Auto/Manual Switch
The Normal Available and Emergency Available (Utility-to-Generator Set)
lamps are lit whenever their corresponding power
sources (utility or generator set) are producing pow- The Auto/Manual switch is used to enable or dis-
er. These two lamps can be lit simultaneously. able the automatic retransfer function. This switch
has two positions. In the Auto position, normal auto-
The Normal Connected and Emergency Con- matic retransfer is enabled. In the Manual position,
nected lamps indicate which power source is con- automatic retransfer (from a functioning generator
nected to the load. Only one of these two lamps can set back to utility power) is disabled; only manual re-
be lit. transfer (using the Test/Normal/Retransfer switch)
is possible. In the event of generator set failure,
Test/Normal/Retransfer Switch however, the Power Sentry control logic will ignore
the Auto/Manual switch and initiate retransfer to
This switch has three positions. In the Normal posi-
utility power.
tion, the transfer switch is set for automatic opera-
tion. Moving the switch to Test sends a start signal Refer to section 6 for a description of the optional
to the generator set. After the transfer time delay, Auto/Manual switch on utility-to-utility transfer
the generator set will assume the load—provided switches.
NORMAL EMERGENCY
AVAILABLE LAMP AVAILABLE LAMP
OPTIONAL AC
VOLTMETER
OPTIONAL AC
AMMETER
PHASE SELECTOR
SWITCH (FOR OPTIONAL FREQUENCY
OPTIONAL METERS) METER
OPTIONAL TEST/NORMAL/
AUTO/MANUAL RETRANSFER SWITCH
SWITCH
M1694−4s
INDICATOR
LAMPS
OPTIONAL
METERS
OPTIONAL
3−WIRE
START
OPTIONAL
EXERCISER
CLOCK
SWITCHES
SC1581
3. Move the Test/Normal/Retransfer switch to An overcrank condition exists when the generator
Test. The generator set should start and run. set fails to start within the time limit. When this con-
dition occurs, the Lockout lamp on the 3-Wire Start
4. At the end of the test period, move the Test/ module will light. To restore the automatic starting
Normal/Retransfer switch to the Normal posi- circuit:
tion. The generator will stop.
5. In anticipation of scheduled or automatic gen- 1. Correct the engine starting problem.
erator set exercise, check that the With/With- 2. Push the Overcrank Reset button and release.
LOCAL TEST
WITH/WITHOUT EMERGENCY
LOAD SELECTOR VOLTAGE SENSOR
SWITCH MODULE
NORMAL
TIME DELAY
VOLTAGE
MODULE
SENSOR
MODULE
PHASE
SELECTOR
SWITCH S2 PHASE
SELECTOR
SWITCH S3
TRANSFORMER
ASSEMBLY
ES1698−2c
CONTROL ES1690
COVER
A series of rectifier bridges receive the AC output The Instant Retransfer input (from the Test/Normal/
from the transformer assembly (connector J6) and Retransfer switch) is optically coupled to the time
rectify it. The rectified voltage (15 to 25 VDC) is delay module to override the retransfer time delay.
used as a reference input for the voltage sensors
and as a power source for the control electronics. On all versions of the mother board, the transfer and
The circuitry for the rectifier bridges is shown in the retransfer inputs are used in conjunction with the
schematics in Section 8. optional signal module relay board. Refer to Op-
tional Control Modules in this section.
Separate voltage regulator circuits receive the out-
put from the Normal and Emergency side rectifier Utility-to-utility and generator set-to-generator set
bridges and regulate the voltages to a constant val- mother boards include Source 1 and Source 2 se-
ue (12 ±0.5 VDC). These circuits provide power for lect inputs. These inputs are wired to the Source
the control relays, display lamps, voltage sensor Selector switch on the cabinet door. Refer to sec-
modules, and time delay module. tion 5 or 6.
Capacitor C1 is large enough (0.1 or 0.47 farads) to Generator set-to-generator set mother boards may
provide power to the time delay module from the include an optional change-over clock input. Refer
time Normal power is lost until Emergency power is to section 5.
available. Refer to Control System Operation.
Switches: There are three switches on the
Additional inputs to the utility-to-generator set 300-3090 mother board and four switches on the
mother board include: 300-3953 mother board.
On the 300-3090 mother board, the K13 test/exer- Voltage Sensor Modules
cise relay is energized by a signal at one of the test/ The voltage sensors are plug-in modules that fit into
exercise inputs. When K13 is energized, its con- the J1 and J3 edge connectors on the mother
tacts 3 and 2 open. This action de-energizes K11, board. The voltage sensors monitor the voltage
starting the generator set. sources (single or three phase) and provide an out-
put signal (Source Available) when the source is
On the 300-3953 mother board, the K13 test/exer- within predetermined limits. Depending on the op-
cise relay is energized by a signal at one of the test/ tions selected, the sensors test for undervoltage,
exercise inputs only when the corresponding With/ overvoltage and under/overfrequency. The Source
Without Load switch is in the Without Load position. Available output signal is latched on when all of the
When K13 is energized, its contacts 3 and 2 open. pickup requirements for voltage and frequency are
This action de-energizes K11, starting the genera- satisfied. The Source Available output signal re-
tor set. mains on until the voltage or frequency goes be-
yond the dropout limits for longer than the corre-
The K13 relay is included only on the utility-to-gener- sponding dropout time delay.
ator set mother board.
Undervoltage sensing is accomplished by sensing
The K14 and K15 transfer and retransfer relays are all voltage phases, but responding only to the low-
energized by signals from the time delay module. est one. Thus, all phases must be above the under-
When energized, their contacts 3 and 4 close to pro- voltage pick-up point before undervoltage pickup
vide power to one of the interposing relays. K14 will occur; while undervoltage dropout will occur
drives the K2 transfer relay. K15 drives the K1 re- when any of the phase voltages fall below the drop-
LAMP INDICATES
Source 1 Available Source 1 voltage is available and within the voltage and frequency settings of the
voltage/frequency sensor.
Source 2 Available Source 2 voltage is available and within the voltage and frequency settings of the
voltage/frequency sensor.
Start Gen Set The control is signaling the generator set to run. This lamp is dimly lit (or off) when
both sources are off.
(Stop) Timing The control is timing out the generator stop delay. At the end of this delay, a stop signal
is sent to the generator set and the Start Gen Set and (Stop) Timing lamps go out.
(Retransfer) Timing Control is timing out for retransfer to Source 1 power. At the end of the timing period,
the lamp goes out and the Retransfer Complete lamp turns on.
(Retransfer) Complete Control is signaling for retransfer to Source 1 power. The Source 1 Available lamp is
also on.
(Transfer) Timing Control is timing out for transfer to Source 2 power. At the end of the timing period,
the lamp goes out and the Transfer Complete lamp turns on.
(Transfer) Complete Control is signaling for retransfer to Source 2 power. The Source 2 Available lamp is
also on.
ES1691−1
TB1
TB3
TB2
ES−1688
The 2-ampere battery charger has an ammeter to FIGURE 2-10. BATTERY CHARGER
indicate charging current and a fuse to protect the
battery charger circuit.
300−3998
SC1574
To set the pickup bandwidth and time delay, align motor can cause severe personal injury. Dis-
the slots on the potentiometers with the desired able the motor, as described below, before mak-
markings on the Power Sentry cover (Figure 2-14). ing adjustments.
Place the Motor Disconnect Switch (on the acces-
Time Delay Module Adjustments sory control panel) in the Off position when making
The time delay module controls the following func- adjustments. Return the switch to the Auto position
tions: after adjustments are completed.
• Start time delay Three-Wire Start
• Stop time delay The 3-Wire Start module has two adjustable timers.
• Transfer time delay The Preheat timer delays the start signal to allow
• Retransfer time delay preheating the generator set. The Preheat timer’s
The time delays on the standard time delay module range of adjustment is 0 to 60 seconds.
are adjustable over the following ranges: If the module has a Preheat On-Off switch, make
sure that it is in the correct position.
Delay Adjustment Range
Start 0 to 15 seconds The Overcrank timer limits the time that the genera-
tor set starter is allowed to operate. The Overcrank
Stop 0 to 10 minutes
timer’s range of adjustment is 0 to 120 seconds.
Transfer 0 to 120 seconds
Retransfer 0 to 30 minutes To set the timers, align the slots on the potentiome-
ters with the desired markings on the faceplate.
An optional time delay module has an adjustable
start delay range of 0 to 90 seconds. Program Transition
The Program Transition module has one adjustable
To set the time delays, align the slots on the poten- timer. The Program Transition time delay holds the
tiometers with the desired markings on the Power transfer switch in the neutral position before allow-
Sentry cover (Figure 2-14). ing it to complete a transfer to the other source.
This module is available with two adjustment
WARNING Automatic transfer switch opera-
ranges; 0 to 7.5 seconds or 0 to 60 seconds.
tion results in rapid movement of the manual
operator handles and presents a hazard of se- To set the time delay, align the slot on the poten-
vere personal injury. Keep hands clear of han- tiometer with the desired marking on the faceplate.
dles when switching back to automatic opera- If a time delay is desired, make sure that the Delay/
tion. No Delay switch is in the Delay position.
If there are no optional control modules to adjust, Signal Module
place the Motor Disconnect Switch in the Auto posi- The Signal Module has one adjustable timer. The
tion and close the cabinet door. Elevator Signal delay controls the timing of two
Exerciser Clock
The exerciser clock initiates generator set start/run
cycles at programmable intervals and for program- SC1579-3
mable durations. It is a 7-day, 24-hour clock that can
store and execute up to ten start/stop programs (ex-
ercise cycles). FIGURE 2-15. EXERCISER CLOCK
Programming the exerciser clock requires setting
the time of day and entering the exercise start and
stop times.
Refer to the circled numbers in Figure 2-15 when
reading the following instructions.
To set the time of day:
1. If you are performing installation and setup,
press the R button (9) with the tip of a ball point
pen to reset all memory. Do not press the R
button if you are only changing the time of day.
2. Press the clock button (1).
3. Press the h button (3) to set the hour of the day.
The clock uses 24-hour (military) time.
4. Press the m button (4) to set the minutes of the
hour.
5. Press the 1-7 button (5) to advance the indica-
tor bar over the desired day number. (Use the 1
to represent Sunday.)
6. Press the Pr button (8) to enter the time.
To set the exercise start time:
1. Slide the output selector switch (16) to the cen-
ter position. The output selector switch has
three positions. The Off position overrides the
program and causes an exercise stop. The I
position overrides the program and causes an
exercise start. The center position selects pro-
gram control.
2. Press the I/O button (2). An “I” (12) appears in
the upper display window. The “I” is a symbol
for start time.
3. Press the h button (3) to set the start hour.
TROUBLE PAGE
Transfer Switch Does Not Retransfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Source 1 Voltage Sensor Does Not Sense Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Transfer Switch Does Not Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Source 2 Voltage Sensor Does Not Sense Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Generator Set Does Not Crank (Two-wire Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Generator Set Does Not Crank (Three-wire Start) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
This procedure is to be performed with the generator set running and Normal voltage
on line. MAKE SURE THAT THE MOTOR DISCONNECT SWITCH IS IN THE AUTO
POSITION.
NOTE: if the Program Transition module is used and transfer switch only moves to
the mid-transition (disconnected) position, the trouble may be in Program Transi-
tion module or relay K3. Place the Delay/No Delay switch in the No Delay position. If
retransfer occurs, replace the Program Transition module.
If retransfer does not occur, replace K3.
When taking voltage measurements, be sure that the probe penetrates the confor-
mal coating on the boards.
1. Is the Retransfer Timing lamp on the time delay board lit? 9 2
2. Is the Retransfer Timing Complete lamp lit? 10 3
3. Is the Source Available lamp on the Source 1 voltage sensor lit? 5 4
4. Refer to Source 1 voltage sensor troubleshooting. X X
5. If the unit is equipped with the Auto/Manual Retransfer selector switch (located 8 6
on the door), is the switch in the Auto position? If the unit doesn’t have the
switch, then go to Step 8.
6. Place the Auto/Manual Retransfer switch in the Auto position. Does the Re- 7 8
transfer Timing lamp on the time delay board come on?
7. Does the transfer switch retransfer after the retransfer time delay? X 1
8. Replace the time delay board. X X
9. Turn the retransfer delay pot (on the time delay board) to minimum (counter- X X
clockwise).
If the Retransfer Timing Complete lamp doesn’t come on within a minute, then
replace the time delay board.
If the Retransfer Timing Complete lamp does come on, but the transfer switch
still doesn’t retransfer, then go to Step 10.
10. Is the Motor Disconnect Switch (on the accessory control panel) in the Auto 12 11
position?
11. Place the Motor Disconnect Switch in the Auto position. If the transfer switch X X
does not retransfer, then go to Step 12.
YES NO
This procedure is to be performed with the generator set running and Normal
voltage on line.
12. If the Signal Module is used, check that the ribbon cable from J4 (on the 13 14
mother board) to the Signal Module is connected properly. If the cable is
OK, then place the Delay/No Delay switch (on the Signal Module) in the No
Delay position. Does the transfer switch retransfer?
13. Replace the Signal Module. X X
14. Place the elevator signal Delay/No Delay switch back in the Delay posi- X X
tion. Go to Step 15.
15. Is there approximately 24 VAC between J7-6 (on the mother board) and 23 16
ground?
16. Is there approximately 24 VAC between J7-7 (on the mother board) and 17 18
ground?
17. Replace the mother board and recalibrate the voltage sensors. X X
18. Is there approximately 24 VAC between TI-X1 and TI-X2 (on the accesso- 19 20
ry control panel)?
19. Either switch S3 (on the transfer switch) is defective or there is an open in X X
the wiring from T1-X1 to J7-7 (on the mother board).
20. Is the correct line voltage present on the primary side of T1 (on the acces- 21 22
sory control panel)?
21. Either the connection at transformer T1 is bad or the transformer itself is X X
bad. Replace the transformer or repair the wiring, as required.
22. If there is line voltage at the Normal lugs of the transfer switch, then there is X X
an open in the wiring from the Normal lugs (Phase A and B) to the primary
side of T1. Find it and repair it.
23. Unplug P2 while watching K1. Does the relay drop out? 25 24
24. Either relay K1 (on the accessory control panel) could be defective or X X
there could be an open in the wiring from J7-6 to K1.
25. There may be an open between K1-9 or K1-7 and the linear motor. The X X
circuit breaker (CB1) could be open or defective, or the linear motor (M1)
could be defective. CB1 and M1 are located on the transfer switch.
TROUBLESHOOTING 3-2
Source 1 Voltage Sensor Does Not Sense Voltage
YES NO
Place the Test With/Without Load switch in the Without Load position.
When taking voltage measurements, be sure that the probe penetrates the
conformal coating on the boards.
1. Are the proper line voltages present at the Normal lugs of the transfer switch? 2 X
2. Are the proper line voltages present at transformer assembly terminal block
A1-TB11 (located below the mother board)? Refer to sheet 3 of 5 in your 3 8
schematic and wiring diagram package.
3. Is there 15 to 25 VAC on the mother board between:
CR20 Cathode and CR24 Cathode? 4 10
CR22 Cathode and CR26 Cathode?
CR16 Cathode and CR18 Cathode?
4. Is there approximately 12 VDC between the CR5 anode (on the mother
board) and ground? 5 9
5. With the voltage sensor removed from slot J1 (on the mother board), is there
15 to 25 VDC between J1-14/J1-15/J1-16 and ground and 20 to 30 VDC be- 6 9
tween J1-17 and ground? If voltages are OK, put the board back in slot J1.
6. If the sensor module is equipped with frequency sensing, is frequency within
limits? 7 X
7. Recalibrate the sensor module, if it can’t be calibrated, then replace the sen-
sor module and calibrate the new one. X X
8. Find and repair an open in the wiring between the Normal lugs on the transfer
switch and the transformer assembly terminal block (located below the moth- X X
er board).
9. Replace the mother board and calibrate the voltage sensors.
10. Perform these steps in the following sequence: X X
A. Replace the transformer board-to-mother board ribbon cable. X X
B. If the source 1 voltage is not sensed, replace the transformer assembly
and recalibrate the sensors.
C. If the source 1 voltage is not sensed, replace the mother board and recal-
ibrate the voltage sensors.
TROUBLESHOOTING 3-3
Transfer Switch Does Not Transfer During a
Power Failure, Test, or Exercise
YES NO
This procedure is to be performed with the generator set running and the Test
switch in the Test position. MAKE SURE THAT THE MOTOR DISCONNECT
SWITCH IS IN THE AUTO POSITION.
NOTE: if the Program Transition module is used and transfer switch only moves
to the mid-transition (disconnected) position, the trouble may be in Program
Transition module or relay K3. Place the Delay/No Delay switch in the No Delay
position. If transfer occurs, replace the Program Transition module.
If transfer does not occur, replace K3.
When taking voltage measurements, be sure that the probe penetrates the
conformal coating on the boards
1. Is the Transfer Timing lamp lit? 6 2
2. Is Source 2 Available lamp lit? 4 3
3. Go to the Source 2 voltage sensor troubleshooting section. X X
4. Is the Transfer Timing Complete lamp on? 7 5
5. Replace the time delay board. X X
6. Turn the transfer delay potentiometer, on the time delay board, to mini- X X
mum (fully counterclockwise). If the Transfer Timing Complete lamp does
not come on within two minutes, then replace the time delay board.
If the Transfer Timing Complete lamp does come on, but the transfer switch still
doesn’t transfer, then go to Step 7.
7. Is the Motor Disconnect switch (on the accessory control panel) in the 9 8
Auto position.
8. Place the Motor Disconnect switch in the Auto position. Does the transfer X 9
switch transfer?
9. If the optional Signal Module is used, check that the ribbon cable from the 10 11
mother board to the option board is connected properly. If the cable is OK,
then place the Delay/No Delay switch (on the option board) in the No
Delay position. Does the switch transfer?
10. Replace the Signal Module. X X
This procedure is to be performed with the generator set running and the Test
switch in the Test position.
11. Place the Signal Module Delay/No Delay switch back in the Delay position. X X
Go to step 12.
12. Is there approximately 24 VAC between J7-4 (on the mother board) and 20 13
ground?
13. Is there approximately 24 VAC between J7-5 (on the mother board) and 14 15
ground?
14. Replace the mother board and recalibrate the voltage sensors X X
15. Is there approximately 24 VAC between T2-X1 and and T2-X2 (located on 16 17
the accessory control panel)?
16. Either switch S7 (located on transfer switch assembly) is defective or there is X X
an open in the wiring from transformer T2-X1 to J7-5 (on the mother board).
17. Is there line voltage on the primary side of T2 (on the accessory control pan-
el)? 18 19
18. Either the connection at transformer T2 is bad or the transformer itself is bad.
Replace the transformer or repair the wiring. X X
19. If there is generator voltage at the Emergency lugs of the transfer switch,
then there is an open in the wiring from the Emergency lugs (Phase A and B) X X
to the primary side of T2.
20. Unplug P2 while watching K2. Does the relay drop out?
21. Either relay K2 (on the accessory control panel) is defective or there is an 22 21
open in the wiring from J7-4 to K2-A. X X
22. There may be an open between K2-9 or K2-7 and the linear motor. The cir-
cuit breaker (CB1) can be open or defective, or the linear motor could be de- X X
fective. Both are located on the transfer switch.
YES NO
This procedure is to be performed with the Normal voltage available and the Test/Nor-
mal/Retransfer switch in the Test position.
When taking voltage measurements, be sure that the probe penetrates the conformal
coating on the boards.
1. Does the generator set crank using the generator set Start switch? 3 2
2. Check the battery voltage. If the battery is low, then charge it or replace it. If X X
battery is OK, then there is a problem with the generator set. Consult the gener-
ator set manual.
3. Check the wiring from the battery to the transfer switch. X X
4. Is there a jumper or closed circuit between TB2-B+ and TB2-2? There should 6 5
NOT be a jumper between TB2-GND and TB2-2.
5. Install a jumper between TB2-B+ and TB2-2. If the generator set does not X X
crank, then go to Step 6.
6. Is there 12 (or 24) VDC between TB2-RMT and ground? 7 9
7. Are the wires from the generator set starting circuit to TB2-B+ and TB2-RMT 9 8
connected properly?
8. Connect wires from the generator set starting circuit to TB2-3 and TB2-4. If the X X
set still does not crank, then go to Step 9.
9. With the Test/Normal/Retransfer switch in the Test position, is there 12 (or 24, if 10 12
applicable) VDC between J7-10 (on the mother board) and ground?
10. Is there 12 (or 24, if applicable) VDC between J8-3 (located on the mother 11 13
board) and ground?
11. There is an open in the wiring from J8-3 (on the mother board) to TB2-4 (on the X X
transfer switch). Find and repair it.
12. There is an open in the wiring from TB2-2 (on the transfer switch) to J7-10 (on X X
the mother board). Find and repair it.
13. Replace the mother board and recalibrate the voltage sensors. X X
This procedure is to be performed with the line voltage available and the Test/Nor-
mal/Retransfer switch in the Test position.
When taking voltage measurements, be sure that the probe penetrates the confor-
mal coating on the boards.
1. Is the battery voltage at approximately 12 VDC? 3 2
2. Charge or replace the battery. X X
3. Is the Auto/Handcrank/Stop switch on the 3-Wire Start module in the Auto 5 4
position?
4. Place the Auto/Handcrank/Stop switch in the Auto position. If the generator X X
set does not crank, go to Step 5.
5. With the Auto/Handcrank/Stop switch in the Handcrank position, can the 7 6
generator set be started from the generator set control?
6. There is a problem with the generator set, consult the generator set service X X
manual.
7. Place the Auto/Handcrank/Stop switch in the Auto position. Is there a jump- 9 8
er from TB2-GND to TB2-2? There should NOT be a jumper from TB2-2 to
TB2-B+.
8. Install a jumper from TB2-GND to TB2-2. If generator set still does not start, X X
then go to step 9.
9. Is there approximately 12 VDC between TB3-1 (located on the left side of the 11 10
cabinet) and ground?
10. Connect the starter battery to TB3-1. X X
11. Is there B+ voltage (12 VDC) at TB3-4? 13 12
12. There is an open in the wiring between TB3 and the generator set. Find and X X
repair it.
13. Is the Overcrank Lockout lamp lit? 14 21
This procedure is to be performed with the line voltage available and the Test/
Normal/Retransfer switch in the Test position.
14. Press and release the Overcrank Reset button. Does the Preheat lamp 15 21
light?
15. After the preheat time delay, does the Overcrank Timing lamp light? 16 23
16. Does the generator set crank? 17 18
17. If the generator set cranks, but does not start, there is a generator set X X
problem.
18. Is there 0 VDC at TB3-4? 19 20
19. There is a generator set problem. X X
20. There is an open between TB3-4 and J11-8 or the 3-WireStart module is X X
bad.
21. Is there 9 to 12 VDC between the anode of CR2 (on the mother board) and 22 24
ground?
22. There is a bad connection in the ribbon cable between the mother board X X
and the 3-Wire Start module.
23. The 3-Wire Start module is bad and must be replaced. X X
24. Replace the mother board and recalibrate the voltage sensors. X X
ACTUATOR
ROD
LINEAR A A
ACTUATOR
ROD END
ASSEMBLY
2
TERMINAL
BRACKET
GROUND
CONNECTION
1 1
VIEW A−A
SC1569s
HEX HEAD
CAPSCREW
WITH LOCK
WASHER
SC1555s
JUMPER 1 1
BUS BAR
JUMPER
BUS BAR
SC1556s
CONTROL WIRING
TERMINAL
10. Apply thread sealant (blue Loctite 242, Onan tion for 40- to 125-ampere switches. Follow
part number 518-0309 is recommended) to the steps 2 through 8 in the Replacing Actuator
threads of the interlock bar machine screws. section. Apply a thin coat of lubricant (Onan
Install the interlock bar and secure to each in- part number 524-0157) to the slot in the handle.
terlock arm with a round head machine screw 13. Test the switch for proper operation and close
and flat washer. Tighten to 15 to 20 in-lbs (1.7 to the cabinet.
2.3 N•m) torque.
11. Attempt to close both sides of the transfer
switch. The interlock assembly must hold one
side open so that only one side closes at at
time.
12. Replace the linear actuator as described in Lin-
ear Actuator Removal And Replacement sec-
SWITCH LEVER IN
CLOSED POSITION
INSULATING
BARRIERS
MACHINE
SCREWS
1
AUXILIARY
SWITCH LEVERS
BRACKETS
SC1557s
ROD END
ASSEMBLY
LINEAR
ACTUATOR
ACTUATOR
ROD
BARRIER 2
TERMINAL
BRACKET
SPACER 3
3
VIEW A−A
1 TORQUE TO 70 TO 75 IN−LBS (7.9 TO 8.5 N•m).
2 TORQUE TO 25 TO 27 IN−LBS (2.8 TO 3.0 N•m).
3 TORQUE TO 25 TO 30 IN−LBS (2.8 TO 3.4 N•m).
sc1558
2
INTERLOCK
ARM
INTERLOCK
2 4
1 4 BAR
sc1560
2
2
INTERLOCK
ARM
INTERLOCK 2
1 4
BAR
4
sc1809
TORQUE TO 10 TO 15 IN−LBS
(1.1 TO 1.7 N•m).
NC
COM
SC1561
BARRIERS
FIGURE 4-10. AUXILIARY SWITCH (150 TO 260 AMPERES)
ROD END
ASSEMBLY
LINEAR
ACTUATOR
ACTUATOR
2 CAPSCREW
BARRIER
TERMINAL
BRACKET
VIEW A−A
SC1562s
ACTUATOR
ACTUATOR
ROD
MOTOR
GROUND
BRUSH
WHITE
RED
BLACK SC1474s
xsc−1417
BLOCK AND
CROSSBAR
1 ASSEMBLY
LUG
TERMINALS
JUMPER 3
BUS BAR
LOAD BUS
JUMPER
BAR
BUS BAR
NEUTRAL
BLOCK AND
1 CROSSBAR
ASSEMBLY
BLOCK AND
CROSSBAR
ASSEMBLY
LUG
TERMINALS
JUMPER
BUS BAR 3
JUMPER
LOAD BUS
BUS BAR
BAR
NO
TORQUE TO 10 TO 15 IN−LBS
(1.1 TO 1.7 N•m). NC
COM
SC1561
BARRIERS
If a generator set provides Emergency power, turn 8. Remove the hex head capscrews, flat wash-
the operation selector switch to Stop. (The selector ers, and lock washers that secure the actuator
switch is located on the generator set control pan- to the switch assemblies (Figure 4-16) and lift
el.) Disconnect both the Normal and Emergency out the spacers and actuator motor.
power sources from the transfer switch. If there Replacing Actuator
is an external battery charger, disconnect it from its
AC power source. Then disconnect the set starting 1. Hold the actuator motor and spacers (4) in
battery (negative [-] lead first). position over the switch assemblies with the
lead wires at the bottom.
WARNING AC power within the cabinet pres- 2. Secure the actuator motor to the switch assem-
ents an electrical shock hazard that can cause blies using hex head capscrews (4), lock wash-
severe personal injury or death. Disconnect all ers (4), and flat washers (4). Tighten the caps-
sources of AC power from the transfer switch crews to 70 to 75 in-lbs (7.9 to 8.5 N•m).
before servicing. 3. Connect the black actuator lead wire to the cir-
cuit breaker, and the red and white actuator
The following procedures cover the removal and re- lead wires to the following capacitor terminals:
placement of the linear actuator for 800- and Red Lead Wire - Connect to capacitor C1 - Ter-
1000-ampere switches. minal 1.
White Lead Wire - Connect to capacitor C2 -
Removing Actuator Terminal 2.
1. Open the transfer switch cabinet door. Transfer switches for voltage ranges 347,
380/416, and 440/480 use two capacitors (C1 and
2. Remove a hex head capscrew, flat washer, and C2) wired together in series. A single jumper
lock washer that secures one of the rod end as- wire is placed between terminal 2 on C1 and ter-
semblies to the end of the actuator rod. minal 1 on C2.
Transfer switches for voltage ranges 115,
3. Remove the rod end assembly (Figure 4-16) 190/200, 208, and 220/240 use two capacitors
and slide the actuator rod out of the actuator (C1 and C2) wired in parallel. Two jumper wires
motor. are used. One is placed between terminal 1 on
C1 and terminal 1 on C2. The other is placed be-
4. Loosen and remove the twelve machine tween terminal 2 on C1 and terminal 2 on C2.
screws (with flat washers) that secure the three 4. Replace the capacitor end cap(s) and install
plastic switch covers to the switch base, and lift the capacitor(s) in the bracket(s).
off the switch covers (Figure 4-16).
5. Connect the ground wire to the end of the ac-
5. Separate the actuator lead wires from the rest tuator. Use wire ties to hold the actuator lead
of the wiring harness; remove the wire ties as wires in place with the rest of the wiring har-
required. ness.
6. Pry the capacitors loose from the brackets. Re- 6. Place the plastic switch covers in position and
move the end cap and disconnect the red and secure with machine screws and flat washers.
white actuator lead wires from the capacitor Tighten to 25 to 30 in-lbs (2.8 to 3.4 N•m)
terminals. torque.
LINEAR
ACTUATOR
ROD END
ASSEMBLY
2 ACTUATOR
ROD
CAPSCREW
2
ACTUATOR
CAPSCREW
SPACER
1
SC1570s
ROD END
ASSEMBLY ACTUATOR
ACTUATOR
ROD
MOTOR
GROUND
BRUSH
RED
WHITE
BLACK
CAPSCREW
WITH LOCK
WASHER
SC1474s
BLOCK 3 JUMPER 2
ASSEMBLY BUS BAR
ARC 1
2 CHUTE
6
ARC CHUTE
4 BARRIER
ARC
CHUTE
SPACER
LOAD BUS
SPACER JUMPER
BAR
BUS BAR
1 TORQUE TO 15 TO 20 IN−LBS (1.7 TO 2.3 N•m). 4 TORQUE TO 28 TO 33 FT−LBS (40.0 TO 44.7 N•m).
2 TORQUE TO 25 TO 30 IN−LBS (2.8 TO 3.4 N•m). 5 TORQUE TO 18 TO 20 FT−LBS (24.4 TO 27.1 N•m).
3 TORQUE TO 70 TO 75 IN−LBS (7.9 TO 8.5 N•m). 6 TORQUE TO 10 TO 12 FT−LBS (13.6 TO 16.3 N•m).
SC1567s
3 2
JUMPER
BUS BAR
BLOCK
ASSEMBLY 1
2 ARC
ARC CHUTE
6 CHUTE
BARRIER
4
ARC
CHUTE
SPACER
1 TORQUE TO 15 TO 20 IN−LBS (1.7 TO 2.3 N•m). 4 TORQUE TO 28 TO 33 FT−LBS (40.0 TO 44.7 N•m).
2 TORQUE TO 25 TO 30 IN−LBS (2.8 TO 3.4 N•m). 5 TORQUE TO 18 TO 20 FT−LBS (24.4 TO 27.1 N•m).
3 TORQUE TO 70 TO 75 IN−LBS (7.9 TO 8.5 N•m). 6 TORQUE TO 10 TO 12 FT−LBS (13.6 TO 16.3 N•m).
SC1568s
2. Remove the hex head capscrew, flat washer, 5. Place the plastic covers in position and secure
and lock washer that secure one of the rod end them with machine screws and flat washers.
assemblies to the end of the actuator rod. Tighten to 25 to 30 in-lbs (2.8 to 3.4 N•m)
torque.
3. Remove the rod end assembly (Figure 4-16)
and slide the actuator rod out of the actuator 6. Insert the actuator rod into the replacement ac-
motor. tuator motor. Hold the actuator ground brush
up slightly to allow passage of the actuator rod.
4. Loosen and remove the twelve machine
screws (with flat washers) that secure the three 7. Secure the rod end assembly to the actuator
plastic switch covers to the switch base, and lift rod with the hex head capscrew, flat washer,
off the switch covers (Figure 4-16). and lock washer. Tighten the capscrew to 70 to
75 in-lbs (7.9 to 8.5 N•m) torque. Fit the rod as-
5. Remove the hex head machine screws that se-
sembly into the handle of the closed switch as-
cure the terminal bracket to the base. Move the
sembly.
bracket to the side to allow access to the auxil-
iary switch terminals. 8. If a generator set is the Emergency power
source, connect the starting battery (negative
6. Remove the control wiring leads from the auxil-
[-] lead last). If applicable, connect the battery
iary switch terminals (Figure 4-20).
charger to its AC power source. Reconnect
7. Close the transfer switch to the side you are the Normal power source and the Emergen-
working on and remove the hex head machine cy power source. Place the operation selec-
screws that secure the auxiliary switch assem- tor switch in the Remote position.
bly brackets to the base. Lift out the auxiliary
switch assembly. 9. Test the transfer switch for proper operation
and close the cabinet.
8. Remove the round head machine screws, Flat
washers, and nuts that secure the auxiliary
switches to the bracket (Figure 4-20); and lift
TORQUE TO 10 TO 15 IN−LBS
(1.1 TO 1.7 N•m).
NC
COM
SC1561
BARRIERS
There are four indicator lamps on the cabinet door. In the Source 1 position, the source 1 generator set
The Source 1 Available and Source 2 Available has priority to run and assume load. The load re-
lamps are lit whenever their corresponding power mains connected to source 1 unless a source 1 fail-
sources are producing power. These two lamps ure is sensed.
can be lit simultaneously.
In the Source 2 position, the source 2 generator set
The Source 1 Connected and Source 2 Connected has priority to run and assume load. The load re-
lamps indicate which power source is connected to mains connected to source 2 unless a source 2 fail-
the load. Only one of these two lamps can be lit. ure is sensed.
SOURCE 1 SOURCE 2
CONNECTED LAMP CONNECTED LAMP
SOURCE 2
SOURCE 1 AVAILABLE LAMP
AVAILABLE LAMP
OPTIONAL AC
VOLTMETER
OPTIONAL AC
AMMETER
PHASE SELECTOR
SWITCH (FOR OPTIONAL FREQUENCY
OPTIONAL METERS) METER
SOURCE
SELECTOR
SWITCH
M1694−3s
INDICATOR
LAMPS
OPTIONAL
METERS
OPTIONAL
3−WIRE
START
OPTIONAL
CHANGE−OVER
CLOCK
SWITCHES
ACCESSORY
CONTROL
PANEL MOTOR OPTIONAL AUTOMATIC
DISCONNECT BATTERY TRANSFER
SWITCH CHARGER SWITCH
SC1581−3s
The AC relays are energized by the same signals FIGURE 5-12. AUXILIARY RELAYS
that power the corresponding indicator lamps on
the cabinet door.
The Emergency and Normal DC relays are ener-
gized to indicate transfer switch position. The Gen-
set Run DC relay is energized only when the 2-wire
start signal is present at the RMT terminal of TB2.
Refer to sheet 1 and to the drawings referenced on
sheet 3 of your schematic and wiring diagram pack-
age.
Refer to the system interconnection drawings, if ap- FIGURE 5-14. STANDBY SET START
plicable. SEQUENCER OPTION
2. Three-wire starting only: The Auto/Stop/ 5. Momentary voltage dips can cause voltage
Handcrank switch on the 3-Wire Start modules sensors to initiate generator set starting.
should be in the Auto position. Check for over- Generator Set Does Not Start
crank condition. (See Operation Section). When a Change-over Is Scheduled
3. Start the generator set using its start-stop con- 1. Two-wire starting only: The operation selec-
trols. (The Auto/Stop/Handcrank switch on the tor switch on the generator set control panel
3-Wire Start module must be in the Handcrank should be in the Remote position.
position.) If it does not crank, check the starting
battery. If it cranks but does not start, check the WARNING AC power within the cabinet
fuel supply. and the rear side of the cabinet door pres-
ents a shock hazard that can cause severe
WARNING Ignition of explosive battery personal injury or death. For this reason;
gases can cause severe personal injury. Do do not touch or allow clothing, tools, or jew-
not smoke or cause any spark or flame elry to contact exposed electrical terminals
while servicing batteries. whenever the cabinet door is open. Make
sure you are standing on a dry, insulating
surface.
WARNING Ignition of fuel can cause se-
vere personal injury or death by fire or ex- 2. Three-wire starting only: The Auto/Stop/
plosion. Do not permit any flame, cigarette, Handcrank switch on the 3-Wire Start module
spark, pilot light, arcing equipment, or oth- should be in the Auto position.
er possible source of ignition near the fuel 3. Check the change-over clock to verify the
system. change-over schedule. The procedure for
checking the change-over program is de-
scribed under Programming the Change-over
Generator Set Starts When Not Scheduled
Clock.
1. Two-wire starting only: The operation selec- If a change-over is incorrectly programmed, re-
tor switch on the generator set control panel fer to the change-over clock programming pro-
should be in the Remote position. cedure.
SOURCE 1 SOURCE 2
CONNECTED LAMP CONNECTED LAMP
SOURCE 2
SOURCE 1 AVAILABLE LAMP
AVAILABLE LAMP
OPTIONAL AC
VOLTMETER
OPTIONAL AC
AMMETER
PHASE SELECTOR
SWITCH (FOR OPTIONAL FREQUENCY
OPTIONAL METERS) METER
OPTIONAL
AUTO/MANUAL
SWITCH
SOURCE
SELECTOR
SWITCH
M1694−2s
INDICATOR
LAMPS
OPTIONAL
METERS
SWITCHES
ACCESSORY
CONTROL
PANEL MOTOR AUTOMATIC
DISCONNECT TRANSFER
SWITCH SWITCH
SC1581−2s
STANDBY
NORMAL CONNECTED LAMP
CONNECTED LAMP
STANDBY
AVAILABLE LAMP
NORMAL
AVAILABLE LAMP
OPTIONAL AC
VOLTMETER
OPTIONAL AC
AMMETER
PHASE SELECTOR
SWITCH (FOR OPTIONAL FREQUENCY
OPTIONAL METERS) METER
LOCAL/REMOTE
SWITCH
NORMAL/STANDBY
SWITCH
M1694−9s
INDICATOR
LAMPS
OPTIONAL
METERS
SWITCHES
TRANSFER
ACCESSORY MOTOR
SWITCH
CONTROL DISCONNECT
ASSEMBLY
PANEL SWITCH
SC1581−1s
cabinet door.
FIGURE 7-5. AUXILIARY RELAYS
Refer to sheet 1 and to the drawings referenced on
sheet 3 of your schematic and wiring diagram pack-
age.
300−3998
SCHEMATIC PAGE
Mother Board 300-3953 (Utility-to-Generator Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Mother Board 300-3267 (Utility-to-Utility) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Mother Board 300-3090 (Utility-to-Generator Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
626-1762 Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
626-1762 Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
626-1762 Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
626-1762 Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
626-1762 Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
MODIFIED
MODIFIED
MODIFIED
ES1973s
626-1762
sh 1 of 5
MODIFIED
626-1762 SHEET 1 OF 5
626-1762
sh 2 of 5
MODIFIED
626-1762 SHEET 2 OF 5
626-1762
sh 3 of 5
MODIFIED
626-1762 SHEET 3 OF 5
626-1762
sh 4 of 5
MODIFIED
626-1762 SHEET 4 OF 5
626-1762
sh 5 of 5
MODIFIED
626-1762 SHEET 5 OF 5
NONAUTOMATIC